US20110052936A1 - Metal-coated steel strip - Google Patents

Metal-coated steel strip Download PDF

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Publication number
US20110052936A1
US20110052936A1 US12/811,213 US81121309A US2011052936A1 US 20110052936 A1 US20110052936 A1 US 20110052936A1 US 81121309 A US81121309 A US 81121309A US 2011052936 A1 US2011052936 A1 US 2011052936A1
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Prior art keywords
coating
particles
alloy
strip
steel strip
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US12/811,213
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English (en)
Inventor
Qiyang Liu
Wayne Renshaw
Joe Williams
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BlueScope Steel Ltd
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BlueScope Steel Ltd
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Priority claimed from AU2008901223A external-priority patent/AU2008901223A0/en
Application filed by BlueScope Steel Ltd filed Critical BlueScope Steel Ltd
Assigned to BLUESCOPE STEEL LIMITED reassignment BLUESCOPE STEEL LIMITED ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: RENSHAW, WAYNE, WILLIAMS, JOE, LIU, QIYANG
Publication of US20110052936A1 publication Critical patent/US20110052936A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
    • C23C2/12—Aluminium or alloys based thereon
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
    • C23C2/06—Zinc or cadmium or alloys based thereon
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/14—Removing excess of molten coatings; Controlling or regulating the coating thickness
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/26—After-treatment
    • C23C2/28—Thermal after-treatment, e.g. treatment in oil bath
    • C23C2/29—Cooling or quenching
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/34—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the shape of the material to be treated
    • C23C2/36—Elongated material
    • C23C2/40—Plates; Strips
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12736—Al-base component
    • Y10T428/1275—Next to Group VIII or IB metal-base component
    • Y10T428/12757—Fe
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771—Transition metal-base component
    • Y10T428/12861—Group VIII or IB metal-base component
    • Y10T428/12951—Fe-base component
    • Y10T428/12972—Containing 0.01-1.7% carbon [i.e., steel]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12771—Transition metal-base component
    • Y10T428/12861—Group VIII or IB metal-base component
    • Y10T428/12951—Fe-base component
    • Y10T428/12972—Containing 0.01-1.7% carbon [i.e., steel]
    • Y10T428/12979—Containing more than 10% nonferrous elements [e.g., high alloy, stainless]

Definitions

  • the present invention relates to strip, typically steel strip, which has a corrosion-resistant metal alloy coating.
  • the present invention relates particularly to a corrosion-resistant metal alloy coating that contains aluminium-zinc-silicon-magnesium as the main elements in the alloy, and is hereinafter referred to as an “Al—Zn—Si—Mg alloy” on this basis.
  • the alloy coating may contain other elements that are present as deliberate alloying additions or as unavoidable impurities.
  • Al—Zn—Si—Mg alloy is understood to cover alloys that contain such other elements and the other elements may be deliberate alloying additions or as unavoidable impurities.
  • the present invention relates particularly but not exclusively to steel strip that is coated with the above-described Al—Zn—Si—Mg alloy and can be cold formed (e.g. by roll forming) into an end-use product, such as roofing products.
  • the Al—Zn—Si—Mg alloy comprises the following ranges in % by weight of the elements aluminium, zinc, silicon, and magnesium:
  • the corrosion-resistant metal alloy coating is formed on steel strip by a hot dip coating method.
  • steel strip In the conventional hot-dip metal coating method, steel strip generally passes through one or more heat treatment furnaces and thereafter into and through a bath of molten metal alloy held in a coating pot.
  • the heat treatment furnace that is adjacent a coating pot has an outlet snout that extends downwardly to a location below the upper surface of the bath.
  • the metal alloy is usually maintained molten in the coating pot by the use of heating inductors.
  • the strip usually exits the heat treatment furnaces via an outlet end section in the form of an elongated furnace exit chute or snout that dips into the bath. Within the bath the strip passes around one or more sink rolls and is taken upwardly out of the bath and is coated with the metal alloy as it passes through the bath.
  • the metal alloy coated strip After leaving the coating bath the metal alloy coated strip passes through a coating thickness control station, such as a gas knife or gas wiping station, at which its coated surfaces are subjected to jets of wiping gas to control the thickness of the coating.
  • a coating thickness control station such as a gas knife or gas wiping station
  • the metal alloy coated strip then passes through a cooling section and is subjected to forced cooling.
  • the cooled metal alloy coated strip may thereafter be optionally conditioned by passing the coated strip successively through a skin pass rolling section (also known as a temper rolling section) and a tension levelling section.
  • the conditioned strip is coiled at a coiling station.
  • a 55% Al—Zn alloy coating is a well known metal alloy coating for steel strip. After solidification, a 55% Al—Zn alloy coating normally consists of ⁇ -Al dendrites and a ⁇ -Zn phase in the inter-dendritic regions of the coating.
  • silicon it is known to add silicon to the coating alloy composition to prevent excessive alloying between the steel substrate and the molten coating in the hot-dip coating method.
  • a portion of the silicon takes part in a quaternary alloy layer formation but the majority of the silicon precipitates as needle-like, pure silicon particles during solidification. These needle-like silicon particles are also present in the inter-dendritic regions of the coating.
  • Mg when Mg is included in a 55% Al—Zn—Si alloy coating composition, Mg brings about certain beneficial effects on product performance, such as improved cut-edge protection, by changing the nature of corrosion products formed.
  • Mg reacts with Si to form a Mg 2 Si phase and that the formation of the Mg 2 Si phase compromises the above-mentioned beneficial effects of Mg in a number of ways.
  • mottling One particular way, which is the focus of the present invention is a surface defect called “mottling”. The applicant has found that mottling can occur in Al—Zn—Si—Mg alloy coatings under certain solidification conditions. Mottling is related to the presence of the Mg 2 Si phase on the coating surface.
  • mottling is a defect where a large number of coarse Mg 2 Si particles cluster together on the surface of the coating, resulting in a blotchy surface appearance that is not acceptable from an aesthetic viewpoint. More particularly, the clustered Mg 2 Si particles form darker regions approximately 1-5 mm in size and introduce non-uniformity in the appearance of the coating which makes the coated product unsuitable for applications where a uniform appearance is important.
  • the present invention is an Al—Zn—Si—Mg alloy coated strip that has Mg 2 Si particles in the coating microstructure with the distribution of Mg 2 Si particles being such that the surface of the coating has only a small proportion of Mg 2 Si particles or is at least substantially free of any Mg 2 Si particles.
  • the applicant has found that when at least 250 ppm Sr, preferably 250-3000 ppm Sr, is added to a coating bath containing an Al—Zn—Si—Mg alloy the distribution characteristics of the Mg 2 Si phase in the coating thickness direction are completely changed by this addition of Sr from the distribution that is present when there is no Sr in the coating bath.
  • these additions of Sr promote the formation of a surface of the coating that has only a small proportion of Mg 2 Si particles or is free of any Mg 2 Si particles and consequently a considerably lower risk of mottling on the surface.
  • the applicant has also found that selecting the cooling rate during solidification of a coated strip exiting a coating bath to be below a threshhold cooling rate, typically below 80° C./sec for coating masses less than 100 grams per square metre of strip surface per side, controls the distribution characteristics of the Mg 2 Si phase so that the surface has only a small proportion of Mg 2 Si particles or is at least substantially free of Mg 2 Si particles, whereby there is a considerably lower risk of Mg 2 Si mottling.
  • a threshhold cooling rate typically below 80° C./sec for coating masses less than 100 grams per square metre of strip surface per side
  • minimising coating thickness variations controls the distribution characteristics of the Mg 2 Si phase so that the surface has only a small proportion of Mg 2 Si particles or is at least substantially free of Mg 2 Si particles, whereby there is a considerably lower risk of Mg 2 Si mottling.
  • the resultant coating microstructure is advantageous in terms of appearance, enhanced corrosion resistance and improved coating ductility.
  • an Al—Zn—Si—Mg alloy coated steel strip that comprises a coating of an Al—Zn—Si—Mg alloy on a steel strip, with the microstructure of the coating comprising Mg 2 Si particles, and with the distribution of the Mg 2 Si particles being such that there is only a small proportion of Mg 2 Si particles or at least substantially no Mg 2 Si particles in the surface of the coating.
  • the small proportion of Mg 2 Si particles in the surface region of the coating may be no more than 10 wt. % of the Mg 2 Si particles.
  • the Al—Zn—Si—Mg alloy comprises the following ranges in % by weight of the elements aluminium, zinc, silicon, and magnesium:
  • the Al—Zn—Si—Mg alloy may also contain other elements, such as, by way of example any one or more of iron, vanadium, chromium, and strontium.
  • the coating thickness is less than 30 ⁇ m.
  • the coating thickness is greater than 7 ⁇ m.
  • the coating contains more than 250 ppm Sr, with the Sr addition promoting the formation of the above distribution of Mg 2 Si particles in the coating.
  • the coating contains more than 500 ppm Sr.
  • the coating contains more than 1000 ppm Sr.
  • the coating contains less than 3000 ppm Sr.
  • the Al—Zn—Si—Mg—Sr alloy coating may contain other elements as deliberate additions or as unavoidable impurities.
  • a hot-dip coating method for forming a coating of a corrosion-resistant Al—Zn—Si—Mg alloy on a steel strip that is characterised by passing the steel strip through a hot dip coating bath that contains Al, Zn, Si, Mg, and more than 250 ppm Sr and optionally other elements and forming an alloy coating on the strip that has Mg 2 Si particles in the coating microstructure with the distribution of the Mg 2 Si particles being such that there is only a small proportion of Mg 2 Si particles or substantially no Mg 2 Si particles in the surface of the coating.
  • the small proportion of Mg 2 Si particles in the surface region of the coating may be no more than 10 wt. % of the Mg 2 Si particles.
  • the coating contains more than 500 ppm Sr.
  • the coating contains at least 1000 ppm Sr.
  • the molten bath contains less than 3000 ppm Sr.
  • the Al—Zn—Si—Mg—Sr alloy coating may contain other elements as deliberate additions or as unavoidable impurities.
  • a hot-dip coating method for forming a coating of a corrosion-resistant Al—Zn—Si—Mg alloy on a steel strip that is characterised by passing the steel strip through a hot dip coating bath that contains Al, Zn, Si, and Mg and optionally other elements and forming an alloy coating on the strip, and cooling coated strip exiting the coating bath during solidification of the coating at a rate that is controlled so that the distribution of Mg 2 Si particles in the coating microstructure is such that there is only a small proportion of Mg 2 Si particles or substantially no Mg 2 Si particles in the surface of the coating.
  • the small proportion of Mg 2 Si particles in the surface region of the coating may be no more than 10 wt. % of the Mg 2 Si particles.
  • the method comprises selecting the cooling rate for coated strip exiting the coating bath to be less than a threshhold cooling rate.
  • the selection of the required cooling rate is related to the coating thickness (or coating mass).
  • the method comprises selecting the cooling rate for coated strip exiting the coating bath to be less than 80° C./sec for coating masses up to 75 grams per square metre of strip surface per side.
  • the method comprises selecting the cooling rate for coated strip exiting the coating bath to be less than 50° C./sec for coating masses of 75-100 grams per square metre of strip surface per side.
  • the method comprises selecting the cooling rate to be at least 11° C./sec.
  • cooling rates are as follows:
  • the coating bath and the coating on steel strip coated in the bath may contain Sr.
  • a hot-dip coating method for forming a coating of a corrosion-resistant Al—Zn—Si—Mg alloy on a steel strip that is characterised by passing the steel strip through a hot dip coating bath that contains Al, Zn, Si, and Mg and optionally other elements and forming an alloy coating on the strip with minimal variation in the thickness of the coating so that the distribution of Mg 2 Si particles in the coating microstructure is such that there is only a small proportion of Mg 2 Si particles or substantially no Mg 2 Si particles in the surface of the coating.
  • the small proportion of Mg 2 Si particles in the surface region of the coating may be no more than 10 wt. % of the Mg 2 Si particles.
  • the coating thickness variation should be no more than 40% in any given 5 mm diameter section of the coating.
  • the coating thickness variation should be no more than 30% in any given 5 mm diameter section of the coating.
  • the selection of an appropriate thickness variation is related to the coating thickness for coating mass).
  • the maximum thickness in any region of the coating greater than 1 mm in diameter should be 27 ⁇ m.
  • the method comprises selecting the cooling rate during solidification of coated strip exiting the coating bath to be less than a threshhold cooling rate.
  • the coating bath and the coating on steel strip coated in the bath may contain Sr.
  • the hot-dip coating method may be the conventional method described above or any other suitable method.
  • the advantages of the invention include the following advantages.
  • the applicant has carried out laboratory experiments on a series of 55% Al—Zn-1.5% Si-2.0% Mg alloy compositions having up to 3000 ppm Sr coated on steel substrates.
  • FIG. 1 summarises the results of one set of experiments carried out by the applicant that illustrate the present invention.
  • the left hand side of the FIGURE comprises a top plan view of a coated steel substrate and a cross-section through the coating with the coating comprising a 55% Al—Zn-1.5% Si-2.0% Mg alloy with no Sr.
  • the coating was not formed having regard to the selection of cooling rate during solidification and coating thickness variations discussed above.
  • the right hand side of the FIGURE comprises a top plan view of a coated steel substrate and a cross-section through the coating, with the coating comprising a 55% Al—Zn-1.5% Si-2.0% Mg alloy and 500 ppm Sr. A complete absence of mottling is evident from the top plan view.
  • the cross-section illustrates upper and lower regions at the coating surface and at the interface with the steel substrate that are completely free of Mg 2 Si particles, with the Mg 2 Si particles being confined to a central band of the coating. This is advantageous for the reasons stated above.
  • the applicant has also carried out line trials on 55% Al—Zn-1.5% Si-2.0% Mg alloy composition (not containing Sr) coated on steel substrates.
  • the trials covered a range of coating masses from 60 to 100 grams per square metre surface per side of strip, with cooling rates up to 90° C./sec.
  • the first factor is the effect of the cooling rate of the strip exiting the coating bath before completing the coating solidification.
  • the applicant found that for a AZ150 class coating (or 75 grams of coating per square metre surface per side of strip—refer to Australia Standard AS1397-2001), if the cooling rate is greater than 80° C./sec, Mg 2 Si particles formed on the surface of the coating. In particular, when the cooling rate was greater than 100° C./sec, mottling occurred.
  • the cooling rate be too low, particularly below 11° C./sec, as in this case the coating develops a defective “bamboo” structure, whereby the zinc-rich phases forms a vertically straight corrosion path from the coating surface to the steel interface, which compromises the corrosion performance of the coating.
  • the cooling rate should be controlled to be in a range of 11-80° C./sec to avoid mottling on the surface.
  • the second important factor found by the applicant is the uniformess of coating thickness across the strip surface.
  • the coating on the strip surface normally had thickness variations that are (a) long range (across the entire strip width, measured by the “weight-strip-weight” method on a 50 mm diameter disc) and (b) short range (across every 25 mm length in the strip width direction, measured in the cross-section of the coating under a microscope with 500 ⁇ magnification).
  • the long range thickness variation is normally regulated to meet the minimum coating mass requirements as defined in relevant national standards.
  • there is no regulation for short range thickness variation as long as the minimum coating mass requirements as defined in relevant national standards are met.
  • the short range coating thickness variation should be controlled to no greater than 40% above the nominal coating thickness within a distance of 5 mm across the strip surface to avoid mottling.
  • the ⁇ -Al phase is the first phase to nucleate.
  • the ⁇ -Al phase then grows into a dendritic form.
  • Mg and Si, along with other solute elements, are rejected into the molten liquid phase and thus the remaining molten liquid in the interdendritic regions is enriched in Mg and Si.
  • the Mg 2 Si phase starts to form, which also corresponds to a temperature around 465° C.
  • region A an interdendritic region near the outer surface of the coating
  • region B another interdendritic region near the quaternary intermetallic alloy layer at the steel strip surface
  • the level of enrichment in Mg and Si is the same in region A as in region B.
  • the Mg 2 Si phase has the same tendency to nucleate in region A as in region B.
  • the principles of physical metallurgy teach us that a new phase will preferably nucleate at a site whereupon the resultant system free energy is the minimum.
  • the Mg 2 Si phase would normally nucleate preferably on the quaternary intermetallic alloy layer in region B provided the coating bath does not contain Sr (the role of Sr with Sr-containing coatings is discussed below).
  • the Mg 2 Si phase Upon nucleation in region B, the Mg 2 Si phase grows upwardly, along the molten liquid channels in the interdendritic regions, towards region A.
  • the molten liquid phase becomes depleted in Mg and Si (depending on the partition coefficients of Mg and Si between the liquid phase and the Mg 2 Si phase), compared with that in region A.
  • a diffusion couple forms between region A and region C.
  • Mg and Si in the molten liquid phase will diffuse from region A to region C.
  • region A is always enriched in Mg and Si and the tendency for the Mg 2 Si phase to nucleate in region A always exists because the liquid phase is “undercooled” with regard to the Mg 2 Si phase.
  • Mg 2 Si phase is to nucleate in region A, or Mg and Si are to keep diffusing from region A to region C, will depend on the level of Mg and Si enrichment in region A, relevant to the local temperature, which in turn depends on the balance between the amount of Mg and Si being rejected into that region by the ⁇ -Al growth and the amount of Mg and Si being moved away from that region by the diffusion.
  • the time available for the diffusion is also limited, as the Mg 2 Si nucleation/growth process has to be completed at a temperature around 380° C., before the L ⁇ Al—Zn eutectic reaction takes place, wherein L depicts the molten liquid phase.
  • controlling the balance between the time available for diffusion and the diffusion distance for Mg and Si can control the subsequent nucleation or growth of the Mg 2 Si phase or the final distribution of the Mg 2 Si phase in the coating thickness direction.
  • the cooling rate should be regulated to a particular range, and more particularly not to exceed a threshhold temperature, to avoid the risk for the Mg 2 Si phase to nucleate in region A.
  • a higher cooling rate will drive the ⁇ -Al phase to grow faster, resulting in more Mg and Si being rejected into the liquid phase in region A and a greater enrichment of Mg and Si, or a higher risk for the Mg 2 Si phase to nucleate, in region A (which is undesirable).
  • a thicker coating (or a thicker local coating region) will increase the diffusion distance between region A and region C, resulting in a smaller amount of Mg and Si being able to move from region A to region C by the diffusion within a set time and in turn a greater enrichment of Mg and Si, or a higher risk for the Mg 2 Si phase to nucleate, in region A (which is undesirable).
  • the cooling rate for coated strip exiting the coating bath has to be in a range of 11-80° C./sec for coating masses up to 75 grams per square metre of strip surface per side and in a range 11-50° C./sec for coating masses of 75-100 grams per square metre of strip surface per side.
  • the short range coating thickness variation also has to be controlled to be no greater than 40% above the nominal coating thickness within a distance of 5 mm across the strip surface to achieve the distribution of Mg 2 Si particles of the present invention.
  • the present invention focuses on (a) the addition of Sr to Al—Zn—Si—Mg coating alloys, (b) cooling rates (for a given coating mass) and (c) control of short range coating thickness variation as means for achieving a desired distribution of Mg 2 Si particles in coatings, i.e. at least substantially no Mg 2 Si particles in the surface of a coating, the present invention is not so limited and extends to the use of any suitable means to achieve the desired distribution of Mg 2 Si particles in the coating.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Thermal Sciences (AREA)
  • Coating With Molten Metal (AREA)
US12/811,213 2008-03-13 2009-03-13 Metal-coated steel strip Abandoned US20110052936A1 (en)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
AU2008901223 2008-03-13
AU2008901223A AU2008901223A0 (en) 2008-03-13 Metal-coated steel strip
AU2008901224A AU2008901224A0 (en) 2008-03-13 Metal -coated steel strip
AU2008901224 2008-03-13
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